Abstract: A method for producing a cylindrical automotive condenser manifold tank (28) provides a regularly spaced series of tube insertion slots (66) located entirely externally to the original outer surface of the blank (34) from which the tank (28) is formed. In addition, the slots (66) are provided by a peripheral bulge (54) that provides a lead in surface and support shelf for the ends (24) of the flat flow tubes (22). The blank (34) is hydroformed between a pair of dies (42, 44) designed to create the desired external surface features, while preserving the round inner surface of the blank (34) without an internal support mandrel.

Abstract: An automotive condenser (10) includes spaced manifold assemblies (18) comprised of semicylindrical tanks (20), matching semicylindrical headers (22) and simple, circular disks (38) serving as manifold separators. The disks (38) are sandwiched between the tank (20) and header (22) with no need for orientation, and with no slots or through notches to pierce the surface of the tank (20) or header (22). The disks (38) sit within matching pairs of common diameter grooves (30, 36) which provide complete, continuous pockets therefore.

Abstract: A multi tube heat exchanger core in which each tube is made from a pair of substantially identical thin sheet metal plates interfitted in a face to face relationship. Each plate has a pair of enlarged protuberances projecting side by side from the upper side surfaces thereof to form tank portions which are adapted to receive the heat exchanger fluid after the plates are built up into a core. The paired plates forming the tubes are mechanically and accurately aligned at their lower side ends by interfitting locking arms and arm receiving slots. To precisely space the tubes from one another so that air centers can be readily installed therebetween, the lower ends of the plates are formed with tube spacing flanges bent perpendicular to the plane of the plate that interlock with one another by tabs and notches.